PROGRAMMABLE LOGIC CONTROLLERS

FOR ELEVATORS

CEA51FA

CONTROLES S.A.

Electrónica Industrial y Telecomunicaciones

Avenida Rivera 3314

Montevideo 11300, Uruguay

Tel.: +598 (2) 622 0651

Fax.: +598 (2) 622 2048

Required Parts:

1 PC with Windows

1 Terminal or HyperTerminal Program of Windows

1 RS232-C/TTL adapter with interface cables

1 Transformer 220/20+20 Vac, 30 VA

The series port to be used must be configured to 9600 baud, 8 bit, 2 stop bit, without parity, no flow control.

With the controller off connect adapter RS232/TTL to the PC.

The ROM with the test software is not inserted.

1) Connect only one side of the transformer secondary winding, to MA and CA1

2) Apply power. After a short delay the power supply indicator red LED must light.

3) Repeat 1) and 2) connecting to MA, CA2

4) Repeat 1) and 2) connecting to MA, CA3

5) Connect both sides of the transformer secondary winding, to MA (center point), CA1 and CA2

6) Apply power. Verify that there is a short delay to light the power supply indicator red LED.

7) Verify the voltage at the +24 terminal (25 Vdc app.) and at 7805 regulator (5 Vdc ± 5%)

8) Power off the controller.

1) connect the RS232/TTL adapter to the controller and to the PC

2) apply power to the PC and to the RS232/TTL adapter

3) in the PC, run the communications software with the appropriate configuration.

Required Parts.

1 E51FA/CEN software (ROM 27256 resident)

1) with the controller off, insert the ROM E51FA/CEN

2. connect the fiber optic transmitter and receiver with about 20 m of fiber.
3. apply power to the controller.

The instructions for the successive steps will appear at the screen.

Required Parts.

1 E51FA/PER software (ROM 27256 resident)

1 60 cm cable kit : red cable with one 1K 1/4W series resistor

black cable

green cable with one 39K 1/4W series resistor

8 strips of 8 red LED's with one 4K7 1/4W series resistor, wired common anode

1 strip of 8 red LED's without series resistor wired common cathode

1) with the controller off, insert the ROM E51FA/PER

2. connect the 8 groups of LED's to terminal ES1 to ES48 and SA1 to SA16, the common anode to +24
3. Connect the 8 common cathode LED's to the terminals SAU1 to SAU8, the common cathode to 0V

4) Connect the red cable with 1K resistor to +24. It will be used to test +24 Vdc active input terminals.

5) Connect the black cable to 0V. It will be used to test 0 Vdc active input terminals

6) Connect the green cable with 39K resistor to 24V. It will be used to test 5 Vdc active input terminals

7) apply power to the controller

A menu appears at the screen:

General Menu

Select one of the options to go to the desired test. Any other key returns to the General Menu.

Option a "Quick automatic": this test verifies that all outputs go on and off.

Open collector outputs in ES1 to ES48 input/output terminals, open collector outputs SA1 to SA16 and R1 to R10 relays are activated sequentially.

Option b "Input/output automatic": this test looks for possible shorts between input/output terminals, from terminal to 0V or to 24V

The input function at input/output terminals is tested sequentially. The screen shows any defect found.

Option c "Main board input": this test looks for possible open paths or shorts in the input/output terminals

Inputs ES1 to ES48, EAU1 to EAU16, ALT, PAS, PAD, SF1, SF2 and SF3 are individually tested.

The operator must apply to each input terminal the nominal voltage for that input. The name of the terminal appears at the screen when the input is activated. The screen shows every name if several inputs are simultaneously activated.

Use black cable for ES1 to ES48 and ALT inputs.

Use red cable for EAU1 to EAU16, PAS and PAD.

Use green cable for SF1, SF2 and SF3.

Option d "Main board relay" test: this test verifies that every relay output goes on and off.

Each relay can be individually activated from the keyboard.

Option e "Main board open collector output": this test verifies that every OC output goes on and off.

Each OC output ES1 to ES48 in the input/output terminals can be individually activated from the keyboard.

These outputs are open collector transistor, normally open, sink current to ground when activated. The common anode LED's must be wired to test these outputs. Otherwise the voltage at the output terminal will be always 0.

Option f "Auxiliary output" (SAUx): this test verifies that every auxiliary output goes on and off.

Each auxiliary output SA1 to SA8 can be individually activated from the keyboard.

These terminals output 0/+5 Vdc in series with a 6K8 resistor.

Output low level must be <0.6 Vdc

Output high level must be >4.5 Vdc

The following steps are supposed to be useful for first level repair. From there on the board should be sent to CONTROLES S.A. or an authorized repair shop.

A careful inspection must be carried out:

• any terminal strip with a damaged terminal must be completely removed.
• any suspicious cooper path (i.e. dark color) must be carefully brushed. Broken paths may be repaired with stained cooper wire 0.1 mm diameter.

- be sure that all the pluggable IC's are OK. If there is a doubt change all them.

Repeat the GENERAL TEST. If the fault continues proceed with the following steps.

A- power supply. Unplug all IC's and verify the DC voltage levels that appear at the power supply circuit diagram.

B- a fault appears while "Controller CPU test" is going on.

If the screen shows a faulty FO communication change the optic fiber and repeat the test.

C- a fault appears while "Input - Output Test" is going on.

This is usually the faulty condition when a controller returns for service, due to erroneous application, high voltage applied at the output or input/output terminals, overvoltage or output shorts when a non fused faulty circuit has been energized. A detailed description follows to guide this usually simple troubleshooting case.

Power the board with a regulated power supply, 24 Vdc, trough terminals 0V and +24 in the lower left terminal strip, to use the voltage references in the text.

Use the ROM 27C256 with software E51FA/PER.

Symptom: all 16 outputs are always on, or blink when activated

1.1 unplug the eight ULN2803.

1.2 with the controller off measure the 33V 1W zener diode (ohm).

if: the zener diode is shorted or it has low resistance value in both senses, go to 1.3

the zener diode appears like a normal rectifier, go to 1.4

1.3 change the zener diode and go to 1.5

1.4 change both ULN2803 and

1.5 power the controller and repeat the test

if: OK, go to step 1.6

else go to step 1.7

1.6 with all the ULN2803 plugged repeat the test.

if: OK, end

else proceed according to the new symptom.

1.7 some of the 16 outputs are always on, or blink when activated

Use the "Main board open collector output" test. Command even outputs and measure the voltage at the output pins of the corresponding 74HCT259. Repeat for the odd outputs. (See CEA51FA diagrams, p. 1.6)

if: the output pin voltage in the 74HCT259 correspond to the command, go to 1.8

otherwise go to 1.9

1.8 Power off the controller and:

verify the series resistor between the 74HCT259 and the ULN2803.

with the ULN2803 unplugged verify the series resistor between them and the terminal strip.

if: faulty resistors or open path or faulty terminal are found, repair it and go to 1.6

1.9 change the faulty 74HCT259 and go to 1.6

2.1 go into and out of the "Main board input" test, and into again, to verify the symptom, proceed as follows and repeat 2.1:

if: none input EAU1 to EAU8 enters, change its 74HCT251

none input EAU9 to EAU16 enters, change its 74HCT251

when one input EAU1 to EAU8 is activated all of them became active, change its 10K SIP array resistor.

when one input EAU9 to EAU16 is activated all of them became active, change its 10K SIP array resistor.

one input EAU1 to EAU8 enters but its LED doesn't light, change its LED. If the symptom repeats change the 10K SIP.

one or more input doesn't enter, check carefully all terminals, paths, change every implied resistor and repeat 2.1. If the symptom repeats change the 74HCT251 and the RC input circuit.

Each input/output terminal is the common point of the high impedance input path and the open collector output path. Each terminal has a pull-up resistor to +24 Vdc. A defect in the output circuit can generate a fault symptom in the input circuit, and inversely.

For an orderly process, follow the following steps:

3.1 go into and out of the "Input/output automatic" test, and into again, to verify the symptom, proceed as follows and repeat 3.1:

if: all inputs faulty and there is a short between ES1 and ES2, go to 3.2

some inputs faulty, go to 3.9

this test OK but some problems arise in "Main board input" test or in "Main board open collector output" test, go to 3.10

3.2 with power applied, verify the voltage at the anode of the 33V 1W zener diode, that should be 21.4 Vdc +/- 0.5 Vdc

if: OK, go to 3.7

the voltage is lower, go to 3.3

3.3 unplug the ULN2803

with the controller off measure the 33V 1W zener diode (ohm).

if: the zener diode is shorted or has low resistance value in both senses, go to 3.5

the zener diode appears like a normal rectifier, go to 13.6

3.5 change the zener diode and go to 3.6

3.6 plug the ULN2803

3.7 run the "Main board open collector output" test

if: OK: go to 3.8

otherwise: go to 3.9

3.8 run the "Input/output automatic" test, then the "Main board input" test and the "Main board open collector output" test.

if : OK: end

a faulty condition appears in the "Main board input" test, go to 3.12

a faulty condition appears in the "Main board open collector output" test, go to 3.9

3.9 some outputs doesn't go on, or off, or blink:

Use the "Main board open collector output" test. Command even outputs and measure the voltage at the output pins of the corresponding 74HCT259. Repeat for the odd outputs. (See CEA51FA diagrams, p. 1.6)

if: the output pin voltage in the 74HCT259 correspond to the command, go to 3.12

otherwise go to 3.11

3.10 Power off the controller and:

verify the series resistor between the 74HCT259 and the ULN2803.

with the ULN2803 unplugged verify the series resistor between them and the terminal strip.

if: faulty resistors or open path or faulty terminal are found, repair it and go to 3.9

3.11 change the faulty 74HCT259 and go to 3.9

3.12 if: all inputs are active or once one input is activated all of them become active: go to 3.13

one or more inputs doesn't enter: go to 3.16

3.13 verify the voltage at the cathode of D21 (1N4004), that should be 22.6 Vdc +/- 0.5 Vdc

if: OK: go to 3.16

otherwise:

3.14 power off the controller and verify D21 (X1 ohm range)

if: D21 open or shorted: change D21 and go to 3.8

otherwise: go to 3.8

3.16 the voltage at each terminal should be 22.0 Vdc +/-1.0 Vdc. If lower, change the 10K SIP that corresponds to that input and run "Main board input" test.

if: OK, go to 3.8

otherwise:

carefully inspect all terminal, path and component, change the 74HCT251 and the RC input circuit and go to 3.8

If this very rare situation appears carefully inspect all terminal, path and component, change the MC14050 IC and the RC input circuit.

Check the series resistors, eventually replace them and run the test. If necessary replace the 74HCT259.

This manual is destined to the personnel of laboratory of electronics in charge of the verification of the operation of controllers CEA51FA and their possible repair, within the considered reach for the service of first degree. One assumes that this personnel has training and experience in this type of works and that the laboratory counts to this end on the sufficient elements and with the electrical diagrams of EXP51FA board.

Required Parts:

1 PC with Windows

1 Terminal or HyperTerminal Program of Windows

1 CEA51FA controller with ROM: EEXP51FA (EXP51FA Test).

1 RS232-C/TTL adapter with interface cables

1 Transformer 220/20+20 Vac and 10+10 Vac 30 VA

The series port to be used must be configured to 9600 baud, 8 bit, 2 stop bit, without parity, no flow control.

With the controller off connect adapter RS232/TTL to the PC.

Install the expansion board EXP51FA over the controller and connect both with the flat cable.

Connect the 20+20 Vac winding to base board terminals CA1, CA2, MA and to expansion board terminals CAE1, CAE2 and MA. MA corresponds to the center tap.

Connect the 10+10 Vac winding to expansion board terminals CAA1, CAA2, CAAC. CAAC corresponds to the center tap.

1) connect the RS232/TTL adapter to the controller and to the PC

1) Apply power to controller and expansion board. After a short delay the power supply indicator red LED in the base board and in the expansion board must light, and the PC shows a message:

CEA51FA Controller

EXP51FA Test

2) If a Z character is sent from the PC to the controller a I character is returned.

3) Put the power off.

1) Connect RS232 controller port to PC using a standard DB9 extension.

2) Apply power. The two LEDs for RS232 line must light green. After a short delay a "2" character is sent to the PC.

3) If an ASCII character is sent from the PC to the controller the following ASCII is returned. I.e., if a S is sent from the PC a T is returned from the EXP51FA. LEDs turn red while the line is active.

4) Put the power off.

1) Connect RS422 controller port to PC using a communications adapter CCA-232/422 and a standard DB9 extension.

2) Apply power. The two LEDs for RS422 line must light green. After a short delay a "5" character is sent to the PC.

3) If an ASCII character is sent from the PC to the controller the following ASCII is returned. I.e., if a 4 is sent from the PC a 5 is returned from the EXP51FA. LEDs turn red while the line is active.

4) Put the power off.

Required Parts.

1 60 cm cable kit : red cable with one 1K 1/4W series resistor

black cable

12 strips of 8 red LED with one 4K7 1/4W series resistor, wired common anode

1) connect the 8 LED groups to terminal ES1 to ES48 and SA1 to SA16, the common anode to +24

2) connect the red cable with 1K resistor to +24. It will be used to test +24 Vdc active input terminals.

3) connect the black cable to 0V. It will be used to test 0 Vdc active input terminals

4) apply power to the controller

To perform this test inputs EAU1 to EAU8 in the base board are associated to relays R11 to R18

If one of these inputs is activated (with the red cable) the corresponding relay closes.

To perform this test inputs ES49 to ES96 in the expansion board are associated to outputs ES1 to ES48 in the base board.

If one of these inputs is activated (with the black cable) the corresponding output closes and the test LED lights.

To perform this test inputs ES1 to ES48 in the base board are associated to outputs ES49 to ES96 in the expansion board.

If one of these inputs is activated (with the black cable) the corresponding output closes and the test LED lights.